1991 MITSUBISHI ECLIPSE differential

21-78MANUAL TRANSAXLE - Special Tools
MD99881 9Installer adapter (40)Installation of front differential bearings
M D998820Installer adapter (42)Installation of center differential bearings and
driven bevel gear bearing
MD999566ClawRemoval of bearing outer race from
intermediate gear, front output shaft, and
center differential
MD998827Installer adapter (56)Installation of drive bevel gear bearing
MB990326Preload socketMeasurement of drive bevel gear shaft
rotating torque
M B990900(included in
MB990988)Side gear holding
Tool (A)Measurement of drive bevel gear shaft
rotating torque
MB991 013Special spannerInstallation and removal of driven bevel gear
lock nut
MB991 193PlugPrevention of transfer oil discharge and
foreign object entry

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MANUAL TRANSAXLE - Transaxle Assembly21-81
i5 r)
p$---al3743-55 Nm
3632-39 ft.lbs.
TFM0029Disassembly steps
I)+ 23. Snap ring
4*24. Viscous couplingl 4 25. Steel ball26. Center shaft
l 27. Transaxle case adapter
28. Outer race
l * 29. Spacer
30. Outer race
l 4 31. Spacer32. Outer race
l * 33. Spacer
34. Center differential
4*35. Outer race$?everse the disassembly procedures to reassemble.
Reverse idler gear shaft bolt(2) +I) : Refer to “Service Points of Disassembly”.l + 36.(3) l + : Refer to “Service Points of Reassembly”.
37. Gasket(4) m : Non-reusable parts.

21-88MANUAL TRANSAXLE - Transaxle Assembly15-22 Nm
11-15 ft.lbs.
-.@&35-42 Nm
26-30 ft.lbs.
\15-22 Nm
11-15 ft.lbs.
/4?2250013
Disassembly steps
38. Clutch oil line bracket
l + 39. Transaxle case
l + 40. Oil guide
l + 41. Oil guide
42. Outer race
l + 43. Spacer
l * 44. Spacer
45. Stopper bracket
l 46. Oil seal
47. Reverse shift lever assembly
48. Reverse shift lever shoe
49. Reverse idler gear shaft
50. Reverse idler gear
51. Front output shaft assembly
52. Needle bearing
53. Front differentialNOTE
(I) Reverse the disassembly procedures to reassemble.(2) l + : Refer to “Service Points of Reassembly”.(3) m : Non-reusable parts.

MANUAL TRANSAXLE - Transaxle Assembly23-95
46. INSTALLATION OF OIL SEALUsing the special tool, install the drive shaft oil seal.
I -.,44.143. INSTALLATION OF SPACER
(1) Place two pieces of approximately 10 mm (39 in.) long,
1.6 mm
(.06 in.) dia. solder at the locations shown on
the transaxle case and install each outer race.
(2) Place two pieces of approximately
10 mm (.39 in.) long,
1.6 mm
(.06 in.) dia. solder at the locations shown on
the bearing outer race.
(3) Install the transaxle case, and tighten bolts to
specifiea-
tion.(4) Remove the transaxle case.
(5) Remove the outer races and remove the solder.
(6) If the solder is not broken, carry out the work in steps
(l)-(5) with large diameter solder.
(7) Using a micrometer, measure the thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Front output shaft preload
0.08-0.13 mm (.0031-.005 in.)
Front differential case end play
0.05-0.17 mm (.0020-.a07 in.)

MANUAL TRANSAXLE - Transaxle Assemblv
I-2mmml
,
Snap r
/ /221012:3(4) Remove the outer races and remove the
solder:(5) If the solder is not broken, carry out the work in steps,
(l)-(4) withlargediameter solder.
(6) Using a micrometer, measure ttie thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Input shaft end play
O-.0.05 mm (O-.0020 in.)
Intermediate gear preload
0.08-0.14 mm (.0031-.005 in.)
Center differential case preload
0.08-0.13 mm (.0031-,005 in.)
27. INSTALLATION OF TRANSAXLE CASE ADAPTER
Apply sealant (liquid gasket) to the transaxle case side of
the transaxle case adapter assembly.
Specified sealant: Mitsubishi genuine sealant Part
No. MD997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuities.
25. INSTALLATION OF STEEL BALL
Move the center shaft so that the steel ball is seated
securely into the groove in center shaft.
23. INSTALLATION OF SNAP RING
Select the snap ring so that the end play in the viscous
coupling is up to specification.
Standard value:
0.1-0.26 mm (.0039-.OlO in.)
18. INSTALLATION OF SHIFT FORK/17.
5TH SPEED SYN-
CHRONIZER ASSEMBLY
Mate the
5th speed shift fork with the 5th gear synchroniz-
er assembly and install them simultaneously.

MANUAL TRANSAXLE - Center Differentid
CENTER DIFFERENTIAL
-4~ DISASSEMBLY AND REASSEMBLY
2210037
-
2250015
Disassembly steps
+* l +1. Taper roller bearing
l + 2. Bolt
l * l +3. Taper roller bearing
4. Output flange
I)* 5. Spacer
6. Side gear
7. Pinion shaft
8. Washer9. Pinion
10. Side gear
l + 11. Spacer
12. Center differential case
FJ)TEeverse the disassembly procedures to reassemble.(2)l *: Refer to “Service Points of Disassembly”.(3)l a: Refer to “Service Points of Reassembly”.
SERVICE POINTS OF DISASSEMBLY
1.13. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the taper roller bearings.
Caution
1. Do not reuse the bearing if it has been removed
from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.

21-104MANUAL TRANSAXLE - Center Differential
Piniongear
MD99881 2
MD998820
TFM0017
SERVICE POINTS OF REASSEMBLY11.
/5. INSTALLATION OF SPACERSI.(1) Install the spacer, side gear, pinion gear, washer, and
pinion shaft into the center differential case.
z
(2) Select and install the thickest spacer that ensures
smooth and light rotation of the pinion gear when
turned while holding the pinion shaft.
(3) Install the side gear, spacer, and output flange, and
tighten bolts to specification.
(4) Select and install the thickest spacer, that allows
smooth rotation of side gear.
(5) Make sure that the two side gears turn smoothly.
Standard value:
Center differential pinion backlash
0.025 - 0.150 mm (.OOOl - .0060 in.)3. INSTALLATION OF TAPER ROLLER BEARINGS
Using the special tool, press-fit the taper roller bearing into
position.Caution
@*Apply the special tool to the inner race only when
.___installing the bearing.
2. INSTALLATION BOLTS
Apply adhesive to the entire thread section of the bolts andquickly tighten bolts to specification in the order shown.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No.4318032
or equivalent
NOTEIf the bolts are to be reused, completely remove the old
adhesive from the threads.
1. INSTALLATION OF TAPER ROLLER BEARINGS
Using the special tool, press-fit the taper roller bearing into
position.Caution
Apply the special tool to the inner race only when
installing the bearing.
6
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21-106MANUAL TRANSAXLE - Front Differential
FRONT DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
NZIMMAG
i;&
Disassembly stepsl + 1. Bolt
2. Differential drive gear
** l +3. Ball bearing+* l * 4. Lock pinI)+ 5. Pinion shaft
l * 6. Pinion
I)+ 7. Washer
l + 8. Sidegear
95-lOl ft.lbs.l * 9. Spacer10. Differential case
NOTE(I)Reverse the disassembly procedures to reassemble(2)C*: Refer to “Service Points of Disassembly”.(3)l +: Refer to “Service Points of Reassembly”.(4)q : Non-reusable parts.
:&
-_-
160015
Press
teal case 2200095
SERVICE POINTS OF DISASSEMBLY3. REMOVAL OF BALL BEARING
Using the special tool, remove the ball bearing.
Caution
Do not reuse the bearing if it has been removed from
the differential case.
4. REMOVAL OF LOCK PIN
Drive out the lock pin from hole A using a punch.